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Lecture-02 (TQM-5S System) PDF

The document discusses the 5S system, a Japanese methodology for organizing and managing the workplace. It describes the 5 steps of 5S - Sort, Set, Shine, Standardize, and Sustain. For each step, it provides examples of activities that can be implemented. The benefits of 5S include increased productivity, improved safety and quality, and reduced waste. Proper implementation and ongoing commitment are needed to sustain the 5S system's benefits.

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Zahid Hasan Opu
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144 views

Lecture-02 (TQM-5S System) PDF

The document discusses the 5S system, a Japanese methodology for organizing and managing the workplace. It describes the 5 steps of 5S - Sort, Set, Shine, Standardize, and Sustain. For each step, it provides examples of activities that can be implemented. The benefits of 5S include increased productivity, improved safety and quality, and reduced waste. Proper implementation and ongoing commitment are needed to sustain the 5S system's benefits.

Uploaded by

Zahid Hasan Opu
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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BGMEA University of Fashion & Technology (BUFT)

Course Title: Total Quality Control Management /


Apparel Quality Control Management
Course Code: AMM 3103 / QLT 4101

Lecture # 2
5S System

Prepared By:
Md. Rafiqul Islam Manik
Assistant Professor & Head
Dept. of AMM, BUFT
5S System/Approach

What is 5S?
❑ 5S is a Japanese method for organizing a workplace.
❑ 5S is a philosophy and a way of organizing and
managing the workplace towards an organized, clean,
high-performance environment with the intent to
improve efficiency by eliminating waste.
❑ It’s sometimes referred to as a housekeeping
methodology.
❑ 5S is amongst the first and fundamental steps
implemented by an enterprise towards the path of
implementing Total Quality Management (TQM) and
continuous improvement at the operation level. It
instils the discipline required to enable each individual
to achieve and maintain a world-class environment.
5S System/Approach

Steps of 5S
5S is literally five abbreviations of Japanese terms with 5
initials of S.
No. of S Japanese English
S-1 Seiri Sort
S-2 Seiton Set
S-3 Seiso Shine
S-4 Seiketsu Standardize
S-5 Sitsuke Sustain
5S System/Approach

S-1: Seiri (Sort)


▪ Focuses on eliminating unnecessary items from the
workplace
▪ Categorize equipment, furniture, tool in your
working place into the following three (03)
categories:
1. Necessary
2. Unnecessary
3. May be necessary
▪ This step will also help with the “just in case”
attitude
5S System/Approach

S-1: Seiri (Sort)


Examples of Sorting -----
▪ Place “Red tag” for categorization of items to identify
unnecessary items
▪ Move unnecessary items (broken and obsolete tools, scrap
and excess raw material etc.) to central stored area
▪ Free up valuable floor space (Space utilization)
▪ Finding abnormality of equipment and tools
▪ Keeping only necessary items
▪ Evaluate necessary items with regard to cost.
5S System/Approach

S-2: Seiton (Set)


▪ “Set” is based on finding efficient and effective
storage of necessary items
▪ Apply “Can see, Can take out, and Can return”
philosophy
▪ This will save time and energy to look for something
5S System/Approach

S-2: Seiton (Set)


Examples of Setting Activities ------
▪ Labeling , numbering, zoning for clear identification of
storage areas to keep necessary items
▪ Set necessary items matching with workflow to minimize
unnecessary movement and transportation time
5S System/Approach

S-3: Seiso (Shine)


▪ Cleaning up one’s workplace daily so that there is no dust
on floors, machines or equipment.
▪ It will create ownership and build pride in the workers
5S System/Approach

S-3: Seiso (Shine)


Examples of Shining Activities ------
▪ Regular cleaning of workplace completely so that
there is no dust anywhere
▪ Cleaning and maintenance of tools and equipment
should be done to prevent deterioration
▪ Periodical check for changes in equipment
▪ Keep workplace easy to work
▪ Keep work place pleasing to work in
5S System/Approach

S-4: Seiketsu (Standardize)


▪ Maintain an environment where S1 to S3 are
implemented in the same manner throughout the
organization.
▪ Give opportunities to employees to take active part in
the development of these standards.
▪ Take the first three ‘S’ and make rules for how and
when these tasks will be performed. These standards
can involve schedules, charts, lists etc.
5S System/Approach

S-4: Seiketsu (Standardize)

Examples of Standardize activities -----


▪ Work instructions, Standard Operating Procedures
(SOPs) will be provided to employees/workers
▪ Checklist development and regular usage for SOPs
▪ Visual checks to maintain the process
▪ Assign task to the responsible personnel
5S System/Approach

S-5: Shitsuke (Sustain)

▪ Maintain S1-S4 through discipline, commitment and


empowerment
▪ It focuses on defining a new mindset and a standard
in workplace
5S System/Approach

S-5: Shitsuke (Sustain)


Examples of ‘Sustain’ Activities ---
▪ Implement work order properly
▪ Regular progress reporting
▪ Refresher training
▪ Periodical evaluation of 5S activities with proper
advices for continuation and further improvements
▪ Appreciation, recognition and awarding on good 5S
activities
▪ To train people to follow discipline independently
▪ Continue to maintain all previous steps
▪ Perform regular audits
5S System/Approach

5S is becoming popular for several reasons ----


1. Visible results enhance the generation of more and
new ideas
2. The workplace gets cleaned up and better organized
3. Operations become easier and safer
4. Results are visible to everyone - insiders and outsiders
5. People are naturally disciplined
6. People take pride in their clean and organized
workplace
7. As a result the company’s good image generates
better
5S System/Approach

Benefits of 5S ………
▪ Increased floor space
▪ Greater self-esteem
▪ Improvement of communication
▪ Increase in productivity
▪ Improved appearance of the organization
▪ Better and constant quality of products and services
▪ Reduced equipment breakdowns
▪ Improves workplace safety
▪ Fewer hazards in workplace
▪ Clean work place
▪ Reduced cycle time
▪ Reduced search time
5S System/Approach

Benefits of 5S ……………. (Cont’d)


▪ Less stress and tiredness
▪ Improved morale and pride in the workplace
▪ Greater efficiency in achieving goals
▪ Greater readiness for new tasks
▪ Better impression on the eye of buyers/clients
5S System/Approach

Ways to Kill 5S
IF YOU ……………………………….
1. Assume 5'S will take place itself without training and
energy
2. Try to accomplish 5'S all at once
3. Try to accomplish 5'S implementation all by yourself
4. Assume that all leaders will understand and lead the
transformation

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